Experts from BAE Systems are using additive manufacturing processes and technologies, including 3D printing, to develop significant structural parts of the aircraft in less time and at reduced cost. The use of Hot Isostatic Press (HIP) technology, which uses extreme heat and pressure to create a solid metal part in any required shape, reduces the time needed to manufacture parts and creates less material waste.
In Warton, Lancashire, test pilots from BAE Systems, Rolls-Royce and the Royal Air Force (RAF) have now flown more than 215 hours of the demonstrator aircraft in a bespoke simulator, providing crucial evidence to support the design of the aircraft and subsequent flight trials years before its first flight, enabling test pilots to become familiar with flying the aircraft.
BAE Systems’ engineers are also using a range of digital simulators and rigs to test cockpit conditions such as heating, cooling and oxygen supply for a pilot without having to use a physical environmental rig.
MBDA is working with BAE Systems to trial digital weapon integration processes for the demonstrator. The aim of these digital techniques is to prove, through test and evaluation, that they will reduce the time and cost for weapons integration. This collaborative approach at this early stage of the programme is already showing potential benefits.
Rolls-Royce is set to deliver two EJ200 engines for installation into the flying demonstrator aircraft following integration testing last year. The engines, donated by the UK Ministry of Defence, will be delivered to BAE Systems in the next 12 months as this collaborative programme continues to make good progress.
This range of novel technologies will demonstrate and test key elements of the next generation combat air design as well as skills, tools, processes and techniques needed to develop Tempest, which will be delivered through the Global Combat Air Programme, with the UK, Italy and Japan.